As everyone strives to maximize warehouse cube space, mezzanine design has emerged as a popular solution to create highly functional and economical workspaces while taking advantage of floor space, vertical space, and everywhere in between. From single-level storage and personnel spaces to multi-level pick modules and sophisticated order processing solutions, the way to match the full spectrum of customer needs is often found by looking up.
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Since mezzanine spaces are fully customizable, permanent structures, it’s important to clearly define your intended use to help determine the design style and anticipated load capacity.
Industrial mezzanines will vary by size, structure, and function but will take form in one of the three construction styles:
Freestanding IWPs and rack-supported structures can be used for similar functions, but they differ in construction style and cost. Both types are typically well-equipped with safety gates and guarding and can be fitted with various decking surfaces depending on the intended use. Choosing a freestanding IWP vs. a rack-supported structure is more about tomorrow’s plans than it is about today’s needs.
IWPs are freestanding structures that typically cost more to build initially, but they are easier to move and reconfigure if future plans suggest that will be necessary. IWPs are multi-purpose industrial mezzanines. They can be designed and constructed for smaller, light-duty applications up to large-span, heavy-duty functions. The five structural framing options are:
In areas where seismic conditions require special considerations, the Moment connection will provide the necessary support and rigidity to allow your operation to still benefit from mezzanine use.
Using moment connection framing secures a rigid connection at the column to prevent rotation and the ensuing overturn at the column base. Typically, a smaller baseplate can be used with a moment connection, and it may also eliminate the need for footings.
Rack-supported mezzanines are less costly to build initially, but with more columns in the design than IWPs, they are more difficult to reconfigure. For a deeper dive into the pros and cons of IWPs and rack-supported mezzanine, check out our comparison blog. The Apex team is also available to help you make the best choice for your operation.
Catwalks are light-capacity passageways built to allow workers to safely move from one point to another without interfering with operations or encountering vehicle traffic. Catwalks are a cost-effective way to improve warehouse safety and take advantage of available vertical space.
When looking to add additional functional space to your warehouse or manufacturing center, you can use a mezzanine(s) for personnel spaces, picking and processing, manufacturing, equipment, and storage. Space and corresponding load capacities will be engineered for the particular function and the structural, mechanical, and safety equipment requirements.
In general, the International Building Code (IBC) parameters specify load capacities from minimum to heavy-duty use in pounds per square foot (psf) distributed across the platform. For example,
Mezzanines should be built to the full expected load capacity of the intended use. It is far more cost-effective to build for heavier capacity from the beginning vs. adding load capacity to an existing structure.
Factors that determine mezzanine capacity:
In addition to intended use, several other factors add to the equation to establish the load capacity of the work platform. From how the weight will be distributed across the mezzanine to the thickness of the warehouse floor and the soil quality underneath, all of these factors are critical in engineering for the desired load capacity. Let’s drill down a bit.
The slab thickness of an industrial facility floor is typically 6”, with 4,000 psi. While this is sufficient for operations up to 25,000 lbs. of rated capacity, the soil quality and/or water table level underneath the floor may reduce the capacity and dictate whether footings are required to erect an IWP.
The next step is to find the uniform load. For example, using the IBC parameters, a light-duty mezzanine has a 125 lbs. per square foot capacity. Taking that number and multiplying it by the projected total sq. ft. of the mezzanine will give you the column loading.
Column loading: total (sq. ft) * 125 (lbs./sq. ft) = lbs. supported by each column.
Note: This is an estimate only. A licensed engineer should always calculate actual load capacity.
Using the column loading, you can then determine the number of columns needed and the spacing to properly support the load uniformly across the total mezzanine and on the specific slab.
The interior columns bear the most weight of the structure even though the columns are usually evenly spaced. Use the interior columns to establish the load capacity. If the warehouse floor can support the interior column loads, it can handle the exterior column load. But remember, the longer the span between the columns, the lower the uniform load.
You will also need to account for concentrated load areas. These are areas where stacked items or machinery will exert extra load in a specific place on the mezzanine over and above the distributed load capacity. Concentrated load areas are considered point loads, and the structure must be designed to support and distribute that weight safely. While considering the load distribution, also delineate between dead vs. live loads. Dead loads are permanent features such as walls, while live loads are moving or movable.
One of the most important cost-saving measures of industrial mezzanine design is to Think Ahead. Anticipate greater mezzanine load capacity where it makes sense. It is more cost-effective to include a higher load capacity in the initial construction than to “add” extra load capacity to the existing structure or deal with construction complications while in the process.
A Mezzanine is an interesting and one of the most suitable options to increase the space on a single floor, but it is still little known. Its many variants make it possible to meet the various needs in terms of layout and constitute exquisite living spaces. But how to design it? Which material and layout to choose for your space?
Indeed, several factors must be considered to build a mezzanine – the type of mezzanine structure, the materials used for the structure (steel, concrete, wood, etc.), the final appearance of the mezzanine, the choice of staircase and railing, and most importantly your budget.
Here’s a detailed explanation of the factors to consider during mezzanine floor construction and some tips for successfully designing a custom mezzanine!
To realise your mezzanine project, it is imperative to respect certain technical aspects. Start by checking the feasibility of your project. Indeed, it is important to have a minimum space of 1.9 meters above the mezzanine’s floor and a minimum space of two meters below.
The thickness of the floor depends on the chosen structure – wood, metal, or composite floor. It can vary from 15 to 30 cm. You, therefore, need a minimum total height of 4.20 m. You should also consider how much weight the existing structures can support. The best is to consult a mezzanine floors Sydney professional.
Tip – take height measurements in at least two places. Existing floors are not always straight!
To build an efficient and inexpensive mezzanine, opt for a simple structure. Take care of the details to obtain an impeccable and classy appearance. Complicated shapes may seem trendy to you. In reality, they quickly go out of fashion and are rarely worth the investment.
Likewise, when it comes to large spaces where the goal of adding a mezzanine floor is to store heavier items or where there will be more foot traffic, the structure will be chosen accordingly.
Raw wood and glulam beams are an option that respects the environment because wood is a renewable material. However, it is important to use certified wood.
A wooden mezzanine does not necessarily have a rustic appearance. The wood used in combination with metal, glass, and contemporary furniture offers a very elegant appearance.
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The floor can be made of wooden joists covered with an OSB plate (the cheapest solution) or a self-supporting dry floor. The floor thickness will be around 20-25cm approximately.
In rustic decor, wood is an obvious choice. If your decor combines a happy mix of wood and steel in a modern spirit, reproduce this juxtaposition of materials in the creation of your mezzanine.
Metal beams can provide longer spans for less thickness. Metal tube joists are a common solution for the floor. The tubes are covered with an OSB floor.
Steel, aluminum, and stainless steel give an impression of lightness and elegance. Gracefully showcasing the handrails (horizontal hand support surface), they will subtly highlight the stairway. These types of materials fit perfectly well with industrial or modern decor.
An alternative solution is a composite floor that consists of a sheet of steel deck covered with cast-in-place concrete. For these two solutions, the floor thickness is less, about 12-15cm.
For its part, the concrete and the stone robustly underline the right angles in value in the industrial decorations. The glass, evoking both purity and space, allows the light to filter inside the mezzanine and to visually integrate it into the overall decor with efficiency.
The construction of the staircase must also respect precise indications to be able to go down and up with ease on the surface of the mezzanine. The commonly accepted standard is that the height of the step and the length of the tread (the space where you place your foot) combined together and multiplied by two must total between 60 and 65 centimetres.
Although it may be tempting to thwart these requirements by installing a ladder instead of a stairway, note that this practice is not safe.
A commonly used formula for staircase design is:
61cm
G= tread height
H= step height
Choose your staircase according to the opening possibilities and the organisation of the room. The straight staircase is the most practical but can be quite long. Stairs with 1/4 or 2/4 turns are frequently chosen. For optimal space saving, you can choose a spiral staircase.
You can also order a custom staircase or opt for a set of stairs- often adjustable and easy to climb, these stairs offer an economical solution. For both solutions, you can find options in wood, metal, or a mixture of both.
The minimum width of a staircase is 74cm. The most common diameters for spiral staircases are 125cm, 140cm, or 160cm.
Tip – incorporate the choice of stairs early in the design phase.
It is stipulated that the guardrail (the barrier at the edge of the stairs that prevents the climbing individual from falling) must be a minimum of 42 inches in height. Limit the space between the various spaces of the guardrail as much as possible, and be aware that it is not allowed to leave a space greater than 3.9 inches between these sections.
The handrail (the horizontal support bar for the hand) must be easy to identify and have no breaks along its surface. Its extremities must not have any irregularities capable of causing injury to a blind person.
The entire ramp (guardrail and handrail) must have a pressure resistance of at least 113 pounds/square foot to prevent more pronounced pressure on it from causing a person to fall.
In short, for the mezzanine railing:
There are several models of mezzanine floors, including:
1. Free-standing mezzanine – This type of mezzanine does not require any additional support from the existing structure and is supported by its own columns.
2. Catwalk mezzanine – This model is used for walkways, platforms, and observation decks, usually found in large warehouses, factories or retail stores.
5. Structural steel mezzanine – This type of mezzanine is built with a stronger framework, making it ideal for heavy-duty applications such as industrial production plants and manufacturing facilities.
6. Column-supported mezzanine – This model is supported by existing columns, eliminating the need for additional support structures.
7. Multi-tier mezzanine – This type of mezzanine involves stacking one mezzanine on top of another, increasing the available floor space in a small area.
It is rather difficult to answer this question since the price will vary depending on several factors discussed above. At first glance, note that the material used will be a major influencing factor.
In addition, the area remains an obvious factor to consider when the time comes to determine the cost of the mezzanine flooring project.
Finally, note that the vocation of the mezzanine will greatly vary the price to be paid. If you need to set up water inlets, electrical outlets, or an air conditioner to make the room functional and habitable, you should not forget to include the costs relating to their installation in your budget.
We recommend you always obtain at least three quotes for constructing your mezzanine.
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